U.S. patent number 5,921,187 [Application Number 08/936,520] was granted by the patent office on 1999-07-13 for pallet structure.
Invention is credited to Neng-Hsin Wang.
United States Patent |
5,921,187 |
Wang |
July 13, 1999 |
Pallet structure
Abstract
A pallet structure includes a rectangular paper blank folded to
define a first side stringer, a second side stringer, and a central
stringer. This paper blank includes: (a) a first folding line
adjacent to a first end portion of the paper blank, wherein the
first folding line defines a first folding flap, (b) a second
folding line adjacent to a second end portion of the paper blank,
wherein the second folding line defines a second folding flap, (c)
a first set of four folding lines, including a third folding line,
a fourth folding line, a fifth folding line, and a sixth folding
line, located between the first and second folding lines, wherein
the first set of four folding lines defines a third folding flap, a
fourth folding flap, and a fifth folding flap, and (d) a second set
of four folding lines, arranged symmetric to the first set of four
folding lines with respect to a center of the paper blank, wherein
the second set of four folding lines includes a seventh folding
line, an eighth folding line, a ninth folding line, and a tenth
folding line, and wherein the second set of four folding lines
defines a sixth folding flap, a seventh folding flap, and an eighth
folding flap. When the paper blank is folded, the first and second
folding flaps are spaced apart from one another and define the
central stringer, the third, fourth, and fifth folding flaps define
the first side stringer, and the sixth, seventh, and eighth folding
flaps define the second side stringer. Additionally, a plurality of
elongated stuffing boards are provided in each of the central
stringer, the first side stringer, and the second side
stringer.
Inventors: |
Wang; Neng-Hsin (Chang Hua
Hsien, TW) |
Family
ID: |
25468755 |
Appl.
No.: |
08/936,520 |
Filed: |
September 24, 1997 |
Current U.S.
Class: |
108/51.3;
108/56.3 |
Current CPC
Class: |
B65D
19/0016 (20130101); B65D 19/0028 (20130101); B65D
2519/00019 (20130101); B65D 2519/00288 (20130101); B65D
2519/00562 (20130101); B65D 2519/00054 (20130101); B65D
2519/00557 (20130101); B65D 2519/00333 (20130101); B65D
2519/00323 (20130101); B65D 2519/00432 (20130101); B65D
2519/00318 (20130101); B65D 2519/00442 (20130101) |
Current International
Class: |
B65D
19/00 (20060101); B65D 019/00 () |
Field of
Search: |
;108/51.3,56.1,56.3,51.11 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
Primary Examiner: Chen; Jose V.
Assistant Examiner: Tran; Hanh V.
Attorney, Agent or Firm: Smith, Gambrell & Russell, LLP
Beveridge, DeGrandi, Weilacher & Young Intellectual Property
Group
Claims
I claim:
1. A pallet structure, comprising:
a rectangular paper blank folded so as to define a first side
stringer, a second side stringer, and a central stringer between
the first side stringer and the second side stringer, wherein the
paper blank includes:
a first folding line adjacent to a first end portion of the paper
blank, wherein the first folding line defines a first folding flap
located at the first end portion,
a second folding line adjacent to a second end portion of the paper
blank, wherein the second folding line defines a second folding
flap located at the second end portion,
a first set of four folding lines, including a third folding line,
a fourth folding line, a fifth folding line, and a sixth folding
line, located between the first folding line and a center of the
paper blank, and wherein the first set of four folding lines
defines a third folding flap, a fourth folding flap, and a fifth
folding flap,
a second set of four folding lines, arranged symmetric to the first
set of four folding lines with respect to the center of the paper
blank, wherein the second set of four folding lines includes a
seventh folding line, an eighth folding line, a ninth folding line,
and a tenth folding line, and wherein the second set of four
folding lines defines a sixth folding flap, a seventh folding flap,
and an eighth folding flap,
wherein a width of the first folding flap is equal to a width of
the third folding flap, wherein a width of the second folding flap
is equal to a width of the sixth folding flap, wherein a width of
the fourth folding flap is equal to a width of the fifth folding
flap, and wherein a width of the seventh folding flap is equal to a
width of the eighth folding flap, and
wherein, when the paper blank is folded, the first and second
folding flaps are spaced apart from one another and define the
central stringer, the third, fourth, and fifth, folding flaps
define the first side stringer, and the sixth, seventh, and eighth
folding flaps define the second side stringer; and
a plurality of elongated stuffing boards provided in each of the
central stringer, the first side stringer, and the second side
stringer.
Description
FIELD OF THE INVENTION
The present invention relates to an improved pallet structure of
the type which is folded from a paper blank that has a rectangular
shape, wherein the paper blank is provided with a plurality of
folding lines adjacent to its end portions which define a pair of
folding flaps. The paper blank further is symmetrically provided
with two sets of four folding lines that symmetrically define two
sets of three folding flaps. The width of the outmost folding flap
is equal to the width of the outer one of the three folding flaps,
while the widths of the other two of the three folding flaps are
equal to one another. When folded, each set of three folding flaps
jointly constructs a side stringer, and a central stringer is
defined by the end folding flaps, which are spaced apart from each
other. The central and the side stringers are filled with a
plurality of elongated stuffing boards respectively. When the
pallet is produced from the paper blank, there is no waste, and the
formation of the pallet from the paper blank can be quickly and
readily conducted.
DESCRIPTION OF THE PRIOR ART
Pallets made from paper board have become more and more popular.
However, pallets made from wood boards and stringers are still used
since wooden pallets may sustain heavier loads than paper pallets.
On the other hand, wooden pallets have rugged surfaces, and the
wooden boards and stringers are attached to each other with metal
nails. This engagement, however, is not durable when the wooden
pallet is lifted by a forklift or crane, as the wooden boards and
stringers are easily broken. Furthermore, the fingers of the
operator may be readily injured by the rugged surface and/or
projected nails of the wooden pallet.
Known pallets made from paper boards, while they may have an
identical shape to wooden pallets, typically do not have sufficient
strength and rigidity. Even if the paper stringers have excellent
strength, the load-sustaining board may be supported only around
the stringers. The load-sustaining board located between two
adjacent stringers is not well supported, and it tends to deflect
or bend when external loads are applied. This deflection is
inevitable.
Other problems are encountered when entrances for the fork of a
forklift are cut or evacuated from a whole and thick paper block
which is configured from a plurality of paper boards. As a result,
there is much waste material formed during the manufacturing
process of the paper pallet. Not only will this waste increase the
manufacturing cost, but it will also increase the inconvenience of
disposing of the waste material. This inconvenience makes users
continue to select wooden pallets instead of paper pallets. This is
really a great loss to the paper pallet industry.
SUMMARY OF THE INVENTION
It is the objective of this invention to provide an improved pallet
structure of the type which is made from a folded paper blank. The
pallet made therefrom is free from any waste material.
In order to achieve the objective set forth, an improved pallet
structure of the type that is folded from a rectangular paper blank
is provided. The paper blank is provided with a plurality of
folding lines adjacent to the end portions of the blank, wherein a
pair of folding flaps are defined respectively by these folding
lines. The paper blank is further symmetrically provided with two
sets of four folding lines which define two sets of three folding
flaps. The width of the outmost folding flap is equal to the width
of the outer one of the three folding flaps, while the widths of
the other two of the three folding flaps are equal to each other.
In this manner, when folded, each set of three folding flaps
jointly constructs a side stringer (such that a pair of side
stringers are produced), while a central stringer is defined by the
outmost folding flaps, which are spaced apart from each other. The
central and the side stringers are filled with a plurality of
elongated stuffing boards, respectively. When the pallet is
produced from the paper blank, there is no waste, and the formation
of the pallet from the paper blank can be quickly and readily
conducted.
According to another aspect of the present invention, a paper blank
is rolled with: (a) four folding lines which are transverse to the
longitudinal direction of the paper blank, such that three folding
flaps are formed between adjacent folding lines, and (b) three
folding lines at each side, such that another three folding flaps
are formed. In this embodiment, the folding flaps located at the
far ends are wider than those in the center. When the paper blank
is folded along the folding lines, U-shaped central and side
stringer portions are formed, and a plurality of elongated stuffing
boards are filled into each of the central and side stringer
portions to increase the rigidity thereof. Then, a covering paper
board is attached such that the openings of the U-shaped central
and side stringer portions are completely enclosed to form a planar
upper surface. Again, in this embodiment, no waste is formed during
the manufacturing process which is simple, fast, and cost
effective.
Still according to another aspect of the present invention, a
pallet is formed from a first paper blank and a second paper blank
which can be attached to the first paper blank. The first paper
blank has a rectangular shape, which is rolled to form three
folding lines adjacent to both ends such that three folding flaps
are respectively formed at each end. The width of the outmost
folding flap is less than the width of the inner folding flaps, and
the width of the outmost folding flap is equal to the width of the
folding flaps of the second paper blank. The second paper blank
also has a rectangular shape, and the central portion thereof is
rolled to form four folding lines such that three folding flaps are
formed therein. When each of the folding lines and flaps are
formed, the first paper blank is folded to form two L-shaped side
stringer portions, and the second paper blank is folded along the
folding lines to form an U-shaped central stringer portion. A
plurality of elongated stuffing boards can be filled into the
central stringer portion to increase the rigidity of the central
stringer, the elongated stuffing boards being interconnected with
the inner wall of the folding flaps. Also, a plurality of elongated
stuffing boards can be filled into the side stringer portions to
increase the rigidity of the side stringer portions, the elongated
stuffing boards being interconnected with the inner wall of the
folding flaps. In this embodiment, the width of one folding flap of
the first paper blank is larger than the other folding flaps, such
that a gap will be formed between the top of the elongated stuffing
boards and the top surface of the first paper blank. The thickness
of the gap is made equal to the thickness of the second paper blank
such that an end portion of the second paper blank can be inserted
and retained within the gap. Again, with this embodiment, during
the manufacturing process, there is no waste left, and the
manufacturing process is simple, fast, and cost effective.
BRIEF DESCRIPTION OF THE DRAWINGS
In order that the present invention may be more readily understood,
the following description is given, merely by way of example, with
reference to the accompanying drawings, in which:
FIG. 1 is a layout of a paper blank according to a first embodiment
of the invention before forming a pallet therefrom;
FIG. 2 is a perspective view of the pallet formed from the paper
blank shown in FIG. 1;
FIG. 3 is an exploded perspective view of another embodiment of a
pallet according to the invention;
FIG. 4 is a perspective view of the pallet shown in FIG. 3;
FIG. 5 is a side elevational view of the paper blank used to form
the pallet shown in FIG. 3;
FIG. 6 is an exploded perspective view of a third embodiment of a
pallet according to the invention; and
FIG. 7 is a perspective view of the third embodiment of the pallet
shown in FIG. 6.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIGS. 1 and 2, the improved pallet structure is made
from a paper blank without generating any waste. The improved
pallet is folded from a paper blank 1 which has been selectively
provided with folding lines. When the paper blank 1 is folded along
the folding lines, the side stringers and central stringer can be
readily formed.
The paper blank 1 has a rectangular shape and is provided with a
plurality of folding lines 11, 11' adjacent to the end portions and
which are transverse to the longitudinal direction of the paper
blank 1. A pair of folding flaps A1, A1' are defined respectively
by folding lines 11, 11', and each of these folding flaps A1 and
A1' have the same width. The paper blank 1 also is symmetrically
provided with eight folding lines 12, 12', 13, 13', 14, 14', 15,
and 15', which symmetrically define three pair of folding flaps A2,
A2', A3, A3', A4 and A4' between adjacent folding lines. The width
of the folding flaps A1, A1', A2, and A2' are equal to each other,
while the width of folding flaps A3, A3', A4, and A4' are wider
than the width of folding flaps A1, A1', A2, and A2'. Each adjacent
set of three folding flaps A2, A3, and A4 and A2', A3', and A4' are
jointly constructed to form the side stringers, and the folding
flaps A1 and A1' jointly define the central stringer. The central
and side stringers have the same height and are spaced with a
preset distance. Once formed, the pallet has a planar bottom
surface. The central stringer can be filled with a plurality of
elongated stuffing boards B which are interconnected with each
other with adhesives. The side stringers can also be filled with a
plurality of elongated stuffing boards C which are interconnected
with each other with suitable adhesives. When the pallet is
produced from the paper blank 1, there is no waste. Furthermore,
the formation of the pallet from the paper blank 1 can be quickly
and readily conducted.
Referring to FIGS. 3, 4, and 5, another paper blank for configuring
a pallet is disclosed. The pallet is configured from a paper blank
2 having a plurality of folding lines for defining a plurality of
folding flaps therebetween, a covering paper sheet 3, and elongated
stuffing boards 4.
The paper blank 2 has a rectangular configuration and is
selectively provided with two sets of three folding lines 21, 22
and 23. After the folding lines 21, 22 and 23 are folded, three
folding flaps D1, D2 and D3 are formed, wherein the width of
folding flap D1 is wider than that of folding flaps D2 and D3.
Another set of folding lines 24, 25, 26 and 27 are also formed
transverse to the longitudinal direction of the paper blank 2. In
the same manner, three folding flaps E1, E2 and E3 are also formed
between adjacent folding lines 24, 25, 26 and 27. When the paper
blank 2 is folded along the predetermined folding lines, the
central and side stringer portions are respectively formed.
A plurality of elongated stuffing boards 4 are filled into the
central and side stringer portions, the stuffing boards being
interconnected with each other and with the folding flaps by
adhesives. By this arrangement, the central and side stringers are
provided with excellent rigidity for sustaining loads.
The covering paper sheet 3 is specially sized to readily cover the
top surface of the pallet such that when the paper sheet 3 covers
the paper blank 2, the opening 28 of each of the stringer portions
can be readily enclosed. As a result, the pallet is provided with a
planar and even top surface.
In the manufacturing process, the paper blank 2 is firstly folded
along the folding lines 21, 22, 23, 24, 25, 26 and 27 such that the
central and side stringer portions are formed. The covering paper
board 3 is covered onto the top of the folded paper blank 2 such
that the opening 28 of the central and side stringer portions are
completely enclosed. The covering paper board 3 is then
interconnected with the inner side walls of the folding flaps E1,
E3, D1 and D3 with adhesives. Afterward, a plurality of elongated
stuffing boards 4 are stuffed into the side and central stringer
portions to increase the rigidity of the stringer portions. In this
manner, an improved pallet is configured. From the foregoing
description, it can be readily appreciated that only a simple
rolling process for forming a plurality of folding lines onto a
paper blank is required. The elongated stuffing board does not need
to be involved in the manufacturing process. As a result, the
manufacturing process as well as labor hours can be significantly
reduced. The manufacturing cost is also advantageously lowered.
Referring to FIGS. 6 and 7, an alternative for making a pallet from
a paper blank is disclosed. In this embodiment, the pallet is
formed from a first paper blank 5 and a second paper blank 6 which
can be attached to the first paper blank 5.
The first paper blank 5 has a rectangular shape, which is rolled to
form two sets of three folding lines 51, 52 and 53, one set
adjacent to each end such that three folding flaps F1, F2 and F3
are respectively formed at the ends. The width of the outmost
folding flap F1 is less than the width of the inner folding flaps
F2 and F3. However, the width of folding flap F1 is equal to the
width of folding flaps G1, G2 and G3 to be formed in the second
paper blank 6.
The second paper blank 6 has a rectangular shape, and the central
portion is rolled with four folding lines 61, 62, 63 and 64 such
that three folding flaps G1, G2 and G3 are formed. The folding
flaps G1, G2 and G3 have equal width.
When each of the folding lines and flaps are formed, the first and
second paper blanks 5 and 6 can be folded to form the side and
central stringer portions, respectively. When the second paper
blank 6 is folded along folding lines 61, 62, 63, and 64, an
U-shaped central stringer portion will be formed from the folding
flaps G1, G2 and G3. Then, a plurality of elongated stuffing boards
8 can be filled into the central stringer portion to increase the
rigidity of the central stringer. The elongated stuffing boards 8
are interconnected with the inner wall of the folding flaps G1 and
G3.
Moreover, the first paper blank 5 is folded along the folding lines
51, 52 and 53 such that a pair of L-shaped side stringer portions
are formed by the folding flaps F1, F2 and F3. When these two
L-shaped side stringer portions are formed, a plurality of
elongated stuffing boards 7 are filled into the stringer portions
to increase the rigidity of the side stringer portions. The
elongated stuffing boards 7 are interconnected with the inner wall
of the folding flaps F1 and F3. Because the width of folding flap
F3 is larger than that of folding flap F1, a gap will be formed
between the top of the elongated stuffing boards 7 and the top
surface of the first paper blank 5. The thickness of the gap is
equal to the thickness of the second paper blank 6 such that the
end portion of the second paper blank 6 can be inserted and
retained within the gap. When the end portions of the second paper
blank 6 are inserted, they can be deployed with adhesives such that
the second paper blank 6 can be fixedly attached to the first paper
blank 5. As is apparently, there is no waste left after the
manufacturing process.
While particular embodiments of the present invention have been
illustrated and described, it would be obvious to those skilled in
the art that various other changes and modifications can be made
without departing from the spirit and scope of the invention. It is
therefore intended to cover in the appended claims all such changes
and modifications that are within the scope of the present
invention.
* * * * *